Time for a Roll Bar

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Time for a Roll Bar

Postby johber41 » 10 Fri Jan, 2014 10:37 pm

I am going to use the bad weather to go ahead and finally install a roll bar. I know that the wife and daughters think it is a good idea. Found a decent home-made roll bar on the Samba which was assembled by a guy in College Station that knows a lot of you guys in the club.
Attachments
Roll Bar Project 1.JPG
Roll Bar Project 1.JPG (63.63 KiB) Viewed 10042 times
Need to Make this out of steel.JPG
Need to Make this out of steel.JPG (59.95 KiB) Viewed 10042 times
Cardboard Pattern 2.JPG
Cardboard Pattern 2.JPG (64.24 KiB) Viewed 10042 times
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Re: Time for a Roll Bar

Postby BrianB » 11 Sat Jan, 2014 8:18 am

Looks like a good start. Single Hoop or are you going to add other bracing? Single is really just considered a "Show Bar" Keep us posted.
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Re: Time for a Roll Bar

Postby johber41 » 12 Sun Jan, 2014 12:26 am

Thanks Brian, I had to fabricate mounts that matched the rounded edge of the rear pan. They turned out better than I expected just a lot of cutting and MIG welding, grinding. I was also lucky I found an old metal support from a hide-a-bed that I was saving. It will be the perfect tie-in to the windshield after some more cutting and welding.

pics attached
Attachments
New Mounts.JPG
New Mounts.JPG (69.99 KiB) Viewed 10021 times
New Mount 2.JPG
New Mount 2.JPG (68.27 KiB) Viewed 10021 times
Windshield Support.JPG
Windshield Support.JPG (56.64 KiB) Viewed 10021 times
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Re: Time for a Roll Bar

Postby Aquabuggy » 12 Sun Jan, 2014 8:27 am

Lookin good !! Keep progress pics coming.
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Re: Time for a Roll Bar

Postby Bill K » 12 Sun Jan, 2014 12:27 pm

:D :D Chris, it's great to see you again on the Forum. How's the Buggy?
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Re: Time for a Roll Bar

Postby johber41 » 12 Sun Jan, 2014 7:51 pm

Got the fabrication done and I am a little disappointed with the thickness of the bed-frame part I used to tie the roll bar to the windshield. I may copy that later in a heavier metal. Now I need to tear it down, paint it , and re-assemble it and I may tack weld the mounts to the pan even though the bolts are giving it plenty of strength. I need to add some plate steel to the bolts underneath the car for some added strength. The roll bar that I am using was designed for rail with bolt-up or weldable connectors fabricated on the back of the bar to receive two down supports. I was going to grind the connectors off, but instead, I might throw some extra stop lights in them. The windshield mount was an easy build, cut from some 4 " rectangular tub steel and pinched in the front so that the windshield can receive it like my convertible top.

pics added
Attachments
Mock-up 1.JPG
Mock-up 1.JPG (75.72 KiB) Viewed 9997 times
Roll Bar Tie-in Closeup.JPG
Roll Bar Tie-in Closeup.JPG (68.4 KiB) Viewed 9997 times
Windshield Tie-in Closeup.JPG
Windshield Tie-in Closeup.JPG (65.33 KiB) Viewed 9997 times
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Re: Time for a Roll Bar

Postby Aquabuggy » 12 Sun Jan, 2014 9:05 pm

I think its a good idea to keep the connectors, ya may want to add the down tubes at some point.

Hey Bill, The buggies are still just collecting dust sitting in the shop. I think we should be in our new house maybe March so hopefully ill be back to bugging in April :D
My name is Chris and well I'm a buggy-aholic

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72 Orange buggy - sold
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68 Manx - viewtopic.php?f=11&t=2509
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Re: Time for a Roll Bar

Postby johber41 » 12 Sun Jan, 2014 11:37 pm

I thought of that Chris, but I have so much going on behind my seats. I have a harbor freight trailer tongue tool box for a trunk and its a place for my convertible top to fold onto and to be snapped down. I have the down tubes, but they are bigger than I would have made them. I understand that the builder intended the setup for a sand rail, not a manx style buggy. The whole set is made of very heavy steel, at least schedule 40. The hoop however is working out for very well for my car with my top folding over and clearing the whole configuration.
Attachments
Conv Top Fits Perfect.JPG
Conv Top Fits Perfect.JPG (61.38 KiB) Viewed 9990 times
Conv Top from rear.JPG
Conv Top from rear.JPG (65.29 KiB) Viewed 9990 times
Top Coverage from front.JPG
Top Coverage from front.JPG (67.87 KiB) Viewed 9990 times
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Re: Time for a Roll Bar

Postby johber41 » 18 Sat Jan, 2014 5:39 pm

Done...for now!
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Done 2.JPG
Done 2.JPG (61.59 KiB) Viewed 9959 times
Done 1.JPG
Done 1.JPG (70.53 KiB) Viewed 9959 times
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Re: Time for a Roll Bar

Postby Ken » 18 Sat Jan, 2014 7:19 pm

Looks great from here John. Look forward to seeing it up close.

Hi Chris, man it seems like its been a really long time. Hope y'all can make a gathering this year. I would be great see the growing family.
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Re: Time for a Roll Bar

Postby johber41 » 19 Sun Jan, 2014 12:41 am

Thanks Ken...hope to see you guys soon.
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Re: Time for a Roll Bar

Postby Joe » 19 Sun Jan, 2014 1:32 pm

It is looking good. Did you make your top for buggy?
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Re: Time for a Roll Bar

Postby johber41 » 19 Sun Jan, 2014 9:48 pm

No, the top is from 1966, I just put a lot of product on it. I really need to get a new one made, but this one will work until I can get the right deal. I have the inside of it reinforced with gorilla glue and tape where it is the weakest.
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Re: Time for a Roll Bar

Postby johber41 » 20 Mon Jan, 2014 6:40 pm

I wired up the roll bar to use the down-tube connectors as turn signals and brake lights. turned out to look pretty nice and it gives me more visibility with other drivers.
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Roll Bar Wired Up.JPG
Roll Bar Wired Up.JPG (67 KiB) Viewed 9911 times
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Re: Time for a Roll Bar

Postby ScottR » 21 Tue Jan, 2014 1:15 am

Looks great. How did you find the lights so fast...and they look like they fit like a glove.
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Re: Time for a Roll Bar

Postby johber41 » 21 Tue Jan, 2014 12:14 pm

I had them in my parts storage...I purchased them on-line for an old 1965 honda s90 motorcycle I rebuilt and they were 6v. They did not fit the application for the bike so I just held on to them. They are LED and they were just shy of fitting into the connectors so I shoved them into a piece of handlebar rubber and they push in nice and snug. Really got lucky I had the parts and that they fit like that. Thanks Scott!
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Re: Time for a Roll Bar

Postby Bill K » 21 Tue Jan, 2014 4:46 pm

Looks like they were made to order. Great job.
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Re: Time for a Roll Bar

Postby johber41 » 21 Tue Jan, 2014 9:28 pm

Thanks Bill
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